intretinere periodica

7/28/2019 intretinere periodica

http://slidepdf.com/reader/full/intretinere-periodica 1/16

Chapter 1Routine maintenance and servicing

Air cleaner element - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Air inlet temperature control check . . . . . . . . . . . . . . . . . . . . . . . . . .28Alternator V-belt check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Automatic transmission check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Automatic transmission fluid level check . . . . . . . . . . . . . . . . . . . . . . .7Automatic transmission fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . .38Bodywork check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Brake pad check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15Brake shoe check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35Clutch cable check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Distributor and HT lead check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Door lock key battery - replacement . . . . . . . . . . . . . . . . . . . . . . . . .24Driveshaft gaiter check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Engine oil and filter - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Fuel filter renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Handbrake linkage check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Headlamp alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Hose and fluid leak check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Idle speed and mixture - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .9Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Intensive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Lock and hinge check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Manual transmission fluid check . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Power steering fluid check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Power steering pump drivebelt check . . . . . . . . . . . . . . . . . . . . . . . .18Radiator inspection and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Rear suspension level control system check . . . . . . . . . . . . . . . . . . .19Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Spark plug renewal (SOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Spark plug renewal (DOHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Steering and suspension check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Throttle linkage maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Timing belt renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Wiring check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1•1

Contents

Easy,suitable fornovice with littleexperience

Fairly easy,suitablefor beginner withsome experience

Fairly difficult,

suitable for competentDIY mechanic

Difficult,suitable forexperienced DIYmechanic

Very difficult,

suitable for expert DIYor professional

Degrees of difficulty

54321



Lubricants and fluidsRefer to “Weekly Checks”

Capacities

Engine oil

Including filter:

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 litres

1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 litres

1.8 and 2.0 litre SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 litres20 XEJ and C 20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 litres

X 20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 litres

Quantity of oil required to raise level on dipstick from “MIN” to “MAX”:

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 litre

All other models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 litre

Cooling system (approx.)

1.4 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 litres

1.6 litre models (except C 16 NZ2) - manual transmission . . . . . . . . . . 5.8 litres

1.6 litre models (except C 16 NZ2) - automatic transmission . . . . . . . . 5.6 litres

C 16 NZ2, 1.8 and 2.0 litre SOHC models - manual transmission . . . . . 7.2 litres

C 16 NZ2, 1.8 and 2.0 litre SOHC models - automatic transmission . . . 7.1 litres

DOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 litres

Transmission

Manual transmission codes:F10 and F13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 litres

F16, F18 and F20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 litres

Automatic - at fluid change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 to 3.5 litres

Difference between dipstick MAX and MIN marks - approximate:

+20°C side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 litre

+80°C side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 litre

Power steering fluid

Approximately . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 litre

Fuel tank

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.0 ±2 litres

Washer fluid

Without headlamp washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 litres

With headlamp washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 litres

EngineOil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion G102

Cooling systemAntifreeze mixture:

28% antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection down to -15°C (5°F)

50% antifreeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection down to -30°C (-22°F)

Note:Refer to antifreeze manufacturer for latest recommendations.

Fuel systemNote: Ignition timing adjustment is not possible on some models, shown for information only.

For further details refer to Chapters 4A or 4B, as applicable.

Idle speed:

14 NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 ±25 rpm

16 SVManual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 ±25 rpmAutomatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . 825 ±25 rpm

18 SV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925 ±25 rpmC 16 NZ and X 16 SZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ±80 rpm

C 16 NZ2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 880 ±80 rpmC 18 NZ

Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 880 ±80 rpmAutomatic transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . 830 ±80 rpm

20 NE, C 20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 ±80 rpm

20 XEJ and C 20 XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 940 ±80 rpmX 20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ±160 rpm

1•2 Servicing Specifications



Idle mixture CO content:

All carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.5%20 NE and 20 SEH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 max.20 XEJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 to 1.2%All other injection models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 % (at 2800 to 3200 rpm)

Air filter element:

1.4 and 1.6 litre ‘round type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W1031.6 and 1.8 litre ‘square type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U5121.8 litre ‘round type’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion type not available2.0 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U554

Fuel filter:

1.6, 1.8 and 2.0 litre ‘in-line’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion L201

Ignition system:Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Chapter 5

Spark plugs

SOHC models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RN9YCC or RN9YCDOHC models:

except C20 XE and X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion RC9MCC *C20 XE and X20 XEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vauxhall P/N 90444724 (FR8LDC)

Plug gap:

RN9YCC and RC9MCC * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mmRN9YC * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 mm

FR8LDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 to 0.8 mm* Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. Where alternative types are used, refer to themanufacturer’s recommendations

Brakes

Minimum pad friction material thickness (including backing plate):

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 mm

Minimum shoe friction material thickness:

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm above rivet heads

Tyres

Tyre size:

51/2 J x 13 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 R13-82T51/2 J x 14 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175/70 R14-82T, 195/60 R14-85H, or 195/60 R14-85V

6J x 15 wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195/60 R15-87V or 205/55 R15-87V

Pressures See “Weekly checks”

Torque wrench settings Nm lbf ft

Automatic transmission drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 33Roadwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 81Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18Engine oil (sump) drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 41

Servicing Specifications 1•3

The maintenance intervals in this manualare provided with the assumption that you,not the dealer, will be carrying out the work.

These are the minimum maintenance intervalsrecommended by the manufacturer forvehicles driven daily. If you wish to keep yourvehicle in peak condition at all times, you maywish to perform some of these proceduresmore often. We encourage frequentmaintenance, because it enhances theefficiency, performance and resale value of your vehicle.

If the vehicle is driven in dusty areas, usedto tow a trailer, or driven frequently at slowspeeds (idling in traffic) or on short journeys,

more frequent maintenance intervals arerecommended. Vauxhall recommend that theservice intervals are halved for vehicles that

are used under these conditions.When the vehicle is new, it should be

serviced by a factory-authorised dealerservice department, to preserve the factorywarranty.

Maintenance is essential for ensuring safetyand for getting the best in terms of performance and economy from your vehicle.Over the years, the need for periodiclubrication - oiling, greasing, and so on - hasbeen drastically reduced, if not eliminated. This has unfortunately tended to lead some

owners to think that because no action is

required, components either no longer exist,

or will last for ever. This is certainly not the

case; it is essential to carry out regular visual

examination comprehensively to spot any

possible defects at an early stage before they

develop into major expensive repairs.

The following service schedules are a list of

the maintenance requirements, and the

intervals at which they should be carried out,

as recommended by the manufacturers.

Where applicable, these procedures are

covered in greater detail near the beginning of

each relevant Chapter.

Maintenance schedule



1•4 Maintenance schedule

Every 250 miles (400 km) or weeklyⅪ Refer to “Weekly checks”

Basic service, every 9000 miles(15 000 km) or 12 months -whichever comes soonerAlong with the items in “Weekly checks”, carry out the

following:Ⅺ Renew the engine oil and oil filter (Section 3).Ⅺ Check all hoses and other components for fluid

leaks (Section 4).Ⅺ Check the steering and suspension components

(Section 5).Ⅺ Check the condition of the driveshaft rubber

gaiters (Section 6).Ⅺ Check the automatic transmission fluid level (if

applicable), (Section 7).Ⅺ Check the radiator for blockage (e.g. dead insects)

and clean as necessary (Section 8).Ⅺ Check and adjust the idle speed and mixture (if

applicable), (Section 9).Ⅺ Check the throttle linkage and lubricate if

necessary (Section 10).Ⅺ Check the exhaust system for corrosion, leaks and

security (Section 11).Ⅺ Check all wiring for condition and security

(Section 12).Ⅺ Check and adjust the ignition timing (if applicable),

(Section 13).

Ⅺ Renew the brake fluid (Section 14).Ⅺ Check the brake pad friction material for wear

(Section 15).Ⅺ Check the handbrake linkage (Section 16).Ⅺ Check the power steering fluid level (if applicable),

(Section 17).Ⅺ Check the power steering pump drivebelt (if

applicable), (Section 18).Ⅺ Check the rear suspension level control system

height, if fitted (Section 19).Ⅺ Check the bodywork (Section 20).Ⅺ Lubricate all locks and hinges (Section 21).Ⅺ Check the alternator V-belt (Section 22).Ⅺ Check the headlamp alignment (Section 23).Ⅺ Replace battery in the door-lock key (if applicable),

(Section 24).Ⅺ Carry out a road test (Section 25).Note: Vauxhall specify that an Exhaust Emissions Test should becarried out at least annually. However, this requires specialequipment, and is performed as part of the MOT test (refer to theend of the manual).

Full service, every 18 000 miles(30 000 km) or 24 months -whichever comes soonerAlong with the ‘basic service’, carry out the following:

Ⅺ Renew the coolant (Section 26).

Ⅺ Renew the air cleaner element (Section 27).

Ⅺ Check the operation of the air cleaner air inlet

temperature control (carburettor models only),

(Section 28).

Ⅺ Renew the fuel filter (Section 29).

Ⅺ Renew the spark plugs (SOHC only), (Section 30) *.Ⅺ Inspect and clean the distributor cap and HT leads

(Section 31).

Ⅺ Check the clutch cable adjustment (Section 32).

Ⅺ Check the manual transmission oil level (Section 33).

Ⅺ Check the automatic transmission (Section 34).

Ⅺ Check the brake drum shoe for wear (Section 35).

Major service, every 36 000 miles(60 000 km) or 48 months -whichever comes soonerAlong with the ‘full service’, carry out the following:

Ⅺ Renew timing belt (Section 36).

Ⅺ Renew the spark plugs (DOHC models only),

(Section 37).

Ⅺ Renew automatic transmission fluid (Section 38) *.* Note: If a vehicle is used for heavy-duty work (e.g. taxi work,caravan/trailer towing, mostly short-distance, stop-start city driving)the fluid must be changed every 36 months or 27 000 miles (45 000km), whichever occurs first.



Maintenance - component location 1•5

Underbonnet view of a 1989 1.6 L model (16 SV engine)

1 VIN plate2 Air cleaner casing *3 Suspension strut top4 Coolant expansion tank

5 Brake fluid reservoir6 Fuel pump7 Steering rack8 Octane rating plug9 Washer fluid reservoir10 Battery11 Ignition coil12 Distributor (Bosch type)13 Cooling fan motor14 Engine oil level dipstick15 Oil filter16 Oil filler cap* Refer to Chapter 4A foralternative type

Underbonnet view of a 1991 model Cavalier 1.6 L (C16 NZ engine)

1 Air cleaner casing2 Suspension strut top3 Coolant expansion tank4 Brake fluid reservoir5 Air box6 Exhaust gas recirculation valve7 Steering gear8 Octane coding plug9 Washer fluid reservoir10 Battery11 Ignition coil12 Distributor13 Cooling fan motor14 Engine oil level dipstick15 Engine oil filter16 Oxygen sensor17 Engine oil filler cap



1•6 Maintenance - component location

Underbonnet view of a 1989 2.0 SRi model (20 SEH engine)

1 VIN plate2 Air cleaner casing3 Airflow meter4 Suspension strut top

5 Coolant expansion tank6 Brake fluid reservoir7 Throttle body8 Relay box9 Octane rating plug10 Washer fluid reservoir11 Battery12 Power steering fluid reservoir13 Power steering fluid hoses14 Distributor cap15 Engine oil level dipstick16 Idle speed adjuster17 Fuel pressure regulator18 Oil filler cap19 Thermostat housing

Underbonnet view of a 1990 GSi 2000 model (20 XEJ engine)

1 VIN plate

2 Air cleaner casing3 Suspension strut top4 Coolant expansion tank5 Brake fluid reservoir6 Air mass meter7 Fuel pressure regulator8 Relay box9 Anti-theft alarm horn10 ABS hydraulic modulator11 Washer fluid reservoir12 Power steering fluid reservoir13 Battery14 Distributor15 Engine oil level dipstick16 Oil filler cap



Maintenance - component location 1•7

Front underbody view of a 1989 1.6 L model (16 SV engine)

1 Brake caliper2 Subframe3 Oil filter4 Clutch cover plate

5 Suspension lower arm6 Differential cover plate7 Engine oil drain plug8 Driveshaft gaiter9 Exhaust pipe10 Anti-roll bar securing nut

Rear underbody view of a 1989 2.0 SRi model (semi-independent rear suspension)

1 Torsion beam2 Trailing arm3 Anti-roll bar4 Shock absorber5 Coil spring6 Exhaust expansion box7 Fuel flow damper8 Fuel filter9 Fuel tank securing strap10 Handbrake cable



1 Introduction

This Chapter is designed to help the home

mechanic maintain his/her vehicle for safety,

economy, long life and peak performance.

The Chapter contains a master maintenance

schedule, followed by Sections dealing specifically

with each task in the schedule. Visual checks,

adjustments, component renewal and other helpful

items are included. Refer to the accompanying

illustrations of the engine compartment and the

underside of the vehicle for the locations of the

various components.

Servicing your vehicle according to the

mileage/time maintenance schedule and the

following Sections will provide a planned

maintenance programme, which should result in a

long and reliable service life. This is a comprehensive

plan, so maintaining some items but not others at

the specified service intervals, will not produce the

same results.

As you service your vehicle, you willdiscover that many of the procedures can -and should - be grouped together, because of the particular procedure being performed, orbecause of the proximity of two otherwise-unrelated components to one another. For

example, if the vehicle is raised for anyreason, the exhaust can be inspected at thesame time as the suspension and steeringcomponents.

The first step in this maintenanceprogramme is to prepare yourself before theactual work begins. Read through all theSections relevant to the work to be carriedout, then make a list and gather all the partsand tools required. If a problem is found, seekadvice from a parts specialist, or a dealerservice department.

2 Intensive maintenance

If, from the time the vehicle is new, routine

maintenance schedule is followed closely

frequent checks made of fluid levels and high-

wear items, as recommended, the engine wil

be kept in relatively good running condition.

The need for additional work will be minimised

It is possible that there will be times when

the engine is running poorly due to the lack of

regular maintenance. This is even more likely

if a used vehicle, which has not received

regular and frequent maintenance checks, is

purchased. In such cases, additional work

may need to be carried out, outside of the

regular maintenance intervals.

If engine wear is suspected, a compression

1•8 Maintenance - component location

Rear underbody view of a 1990 GSi 2000 model (fully independent rear suspension)

1 Fuel tank securing strap2 Shock absorber3 ABS wheel sensor4 Semi-trailing arm5 Suspension crossmember

mounting bracing bracket6 Handbrake cable7 Suspension crossmember8 Exhaust expansion box9 Fuel pump

Maintenance procedures



test (refer to Chapter 2A) will provide valuableinformation regarding the overall performance

of the main internal components. Such a test

can be used as a basis to decide on theextent of the work to be carried out. If, for

example, a compression test indicates seriousinternal engine wear, conventional

maintenance as described in this Chapter willnot greatly improve the performance of the

engine. It may also prove a waste of time andmoney, unless extensive overhaul work is

carried out first.

The following series of operations are thosemost often required to improve the

performance of a generally poor-runningengine:

Primary operations

a) Clean, inspect and test the battery (See“Weekly Checks”)

b) Check all the engine related fluids (See“Weekly Checks”)

c) Check the condition and tension of theauxiliary drivebelt (Sections 18 and 22, asappropriate).

d) Renew the spark plugs (Sections 30 and37, as appropriate).

e) Inspect the distributor cap, rotor arm andHT leads, as applicable (Section 31).

f) Check the condition of the air filter, andrenew if necessary (Section 27).

g) Check the fuel filter (Section 29).h) Check the condition of all hoses, and

check for fluid leaks (Section 4).

i) Check the idle speed and mixturesettings, as applicable (Section 9).

5 If the above operations do not prove fullyeffective, carry out the following secondaryoperations:

Secondary operations

All items listed under “Primary operations”,plus the following:

a) Check the charging system (Chapter 5).b) Check the ignition system (Chapter 5).c) Check the fuel system (Chapters 4A and

4B).d) Renew the distributor cap and rotor arm

(Section 31).e) Renew the ignition HT leads (Section 31).

3 Engine oil and filter- renewal

21 Ideally, the oil should be drained with theengine hot, just after the vehicle has beendriven.2 On DOHC models, remove the engineundershield to expose the sump drain plugand the oil filter.3 Place a container beneath the oil drain plugat the rear of the sump.4 Remove the oil filler cap from the camshaftcover, then using a socket or spanner,unscrew the oil drain plug, and allow the oil todrain (see illustration). Take care to avoidscalding if the oil is hot.

5 Allow ten to fifteen minutes for the oil todrain completely, then move the containerand position it under the oil filter.

6 On 1.8 and 2.0 litre models, improvedaccess to the oil filter can be gained by jacking up the front of the vehicle and

removing the right-hand roadwheel (seeillustration). Ensure that the handbrake isapplied, and that the vehicle is securelysupported on axle stands (see “ J acking andVehicle Support”). Note that further oil maydrain from the sump as the vehicle is raised.7 Using a strap wrench or a filter removal toolif necessary, slacken the filter and unscrew itfrom the mounting. Alternatively, if the filter isvery tight, a screwdriver can be driventhrough the filter casing and used as a lever.Discard the filter.

8 Wipe the mating face on the filter mountingwith a lint-free rag, then smear the sealing ringof the new filter with clean engine oil of the

specified grade.9 Screw the new filter into position andtighten it by hand only, do not use any tools.

10 Where applicable, refit the roadwheel andlower the vehicle to the ground. Fully tightenthe roadwheel bolts with the vehicle resting onits wheels.

11 Examine the condition of the oil drain plugsealing ring and renew if necessary, then refitthe drain plug and tighten it to the specifiedtorque.

12 Refill the engine through the filler on thecamshaft cover, using the specified grade andquantity of oil. Fill until the level reaches the

“MAX” mark on the dipstick, allowing time forthe oil to drain through the engine to thesump.13 Refit the oil filler cap, then start the engineand check for leaks. Note that the oil pressurewarning lamp may stay illuminated for a fewseconds when the engine is started as the oilfilter fills with oil.14 Stop the engine and recheck the oil level,topping-up if necessary.15 On DOHC models, refit the engineundershield.16 Dispose of the old engine oil safely; do notpour it down a drain.

4 Hose and fluid leak check 11 Visually inspect the engine joint faces,gaskets and seals for any signs of water or oilleaks. Pay particular attention to the areasaround the camshaft cover, cylinder head, oifilter and sump joint faces. Remember that,over a period of time, some very slightseepage from these areas is to be expected -what you are really looking for is anyindication of a serious leak. Should a leak befound, renew the offending gasket or oil seaby referring to the appropriate Chapters in thismanual.

Every 9000 miles or 12 months 1•9

3.6 Oil filter viewed through right-handwheel arch - SOHC model

3.4 Sump drain plug location -2.0 litre DOHC model

(engine undershield removed)

Basic service, every 9000 miles (15 000 km) or 12 months

As the drain plug releasesfrom the threads, move itaway quickly so the streamof oil, running out of the

sump, goes into the container not upyour sleeve (see illustration).

Note: It is

antisocial and

illegal to dump oil

down the drain.

To find the

location of your

local oil recycling

bank, call this

number free.



2 Also check the security and condition of allthe engine related pipes and hoses. Ensurethat all cable-ties or securing clips are inplace, and in good condition. Clips that arebroken or missing can lead to chafing of thehoses, pipes or wiring, which could causemore serious problems in the future.3 Carefully check the radiator hoses andheater hoses along their entire length. Renew

any hose that is cracked, swollen ordeteriorated. Cracks will show up better if thehose is squeezed. Pay close attention to thehose clips that secure the hoses to thecooling system components. Hose clips canpinch and puncture hoses, resulting in coolingsystem leaks. It is always beneficial to renewhose clips whenever possible.4 Inspect all the cooling system components(hoses, joint faces, etc.) for leaks.

5 Where any problems are found on systemcomponents, renew the component or gasket

with reference to Chapter 3.6 Where applicable, inspect the automatictransmission fluid cooler hoses for leaks ordeterioration.7 With the vehicle raised, inspect the petroltank and filler neck for punctures, cracks andother damage. The connection between thefiller neck and tank is especially critical.Sometimes a rubber filler neck or connectinghose will leak due to loose retaining clamps ordeteriorated rubber.8 Carefully check all rubber hoses and metalfuel lines leading away from the petrol tank.Check for loose connections, deterioratedhoses, crimped lines, and other damage. Payparticular attention to the vent pipes and

hoses, which often loop up around the fillerneck and can become blocked or crimped.Follow the lines to the front of the vehicle,carefully inspecting them all the way. Renewdamaged sections as necessary.9 From within the engine compartment,check the security of all fuel hose attachmentsand pipe unions, and inspect the fuel hosesand vacuum hoses for kinks, chafing anddeterioration.10 Where applicable, check the condition of the power steering fluid hoses and pipes.

5 Steering and suspensioncheck 2

Front suspension and steeringcheck

1 Raise the front of the car, and support on

axle stands (“ J acking and Vehicle Support”).2 Visually inspect the balljoint dust coversand the steering rack-and-pinion gaiters forsplits, chafing or deterioration. Any wear of these components will cause loss of lubricant,together with dirt and water entry, resulting inrapid wear of the balljoints or steering gear.3 On vehicles with power steering, check thefluid hoses for chafing or deterioration, andthe pipe and hose unions for fluid leaks. Alsocheck for signs of fluid leakage underpressure from the steering gear rubbergaiters, which would indicate failed fluid sealswithin the steering gear.4 Grasp the roadwheel at the 12 o’clock and6 o’clock positions, and try to rock it (seeillustration). Very slight free play may be felt,but if the movement is appreciable, furtherinvestigation is necessary to determine thesource. Continue rocking the wheel while anassistant depresses the footbrake. If themovement is now eliminated or significantlyreduced, it is likely that the hub bearings areat fault. If the free play is still evident with thefootbrake depressed, then there is wear in thesuspension joints or mountings.5 Now grasp the wheel at the 9 o’clock and 3o’clock positions, and try to rock it as before.Any movement felt now may again be causedby wear in the hub bearings or the steeringtrack-rod balljoints. If the inner or outer balljoint

is worn, the visual movement will be obvious.6 Using a large screwdriver or flat bar, checkfor wear in the suspension mounting bushesby levering between the relevant suspensioncomponent and its attachment point. Somemovement is to be expected as the mountingsare made of rubber, but excessive wearshould be obvious. Also check the conditionof any visible rubber bushes, looking for splits,cracks or contamination of the rubber.7 Inspect the front suspension lower arms fordistortion or damage (Chapter 10, Section 5).8 With the car standing on its wheels, have anassistant turn the steering wheel back andforth about an eighth of a turn each way. There should be very little, if any, lostmovement between the steering wheel androadwheels. If this is not the case, closelyobserve the joints and mountings previouslydescribed, but in addition, check the steeringcolumn universal joints for wear, and the rack-and-pinion steering gear itself.

Suspension strut/shockabsorber check

Note: Suspension struts/shock absorbersshould always be renewed in pairs on thesame axle.

9 Check for any signs of fluid leakage aroundthe suspension strut/shock absorber body, orfrom the rubber gaiter around the piston rodShould any fluid be noticed, the suspensionstrut/shock absorber is defective internallyand should be renewed.10 The efficiency of the suspensionstrut/shock absorber may be checked by

bouncing the vehicle at each corner. The bodywill return to its normal position and stop afterbeing depressed. If it rises and returns on arebound, the suspension strut/shockabsorber is probably suspect. Examine alsothe suspension strut/shock absorber upperand lower mountings for any signs of wear.

6 Driveshaft gaiter check 2With the vehicle raised and securely

supported on stands, turn the steering ontofull lock, then slowly rotate the roadwheel.

Inspect the condition of the outer constantvelocity (CV) joint rubber gaiters, squeezingthe gaiters to open out the folds (seeillustration). Check for signs of cracking,splits or deterioration of the rubber, whichmay allow the grease to escape, and lead towater and grit entry into the joint. Also checkthe security and condition of the retainingclips. Repeat these checks on the inner CV joints. If any damage or deterioration is foundthe gaiters should be renewed as described inChapter 8.

1•10 Every 9000 miles or 12 months

6.1 Check the condition of the driveshaftgaiters (A) and clips (B)

5.4 Check for wear in the hub bearings bygrasping the wheel and trying to rock it

A leak in the cooling system will usuallyshow up as white or rust coloureddeposits on the area adjoining the leak



At the same time, check the generalcondition of the CV joints themselves by firstholding the driveshaft and attempting torotate the wheel. Repeat this check by holdingthe inner joint and attempting to rotate thedriveshaft. Any appreciable movementindicates wear in the joints, wear in thedriveshaft splines, or a loose driveshaftretaining nut.

7 Automatic transmission fluidlevel check 2

Note: The transmission fluid level can bechecked either when it is cold (only below35ºC (100ºF) outside temperature) or when it isfully warmed up to normal operatingtemperature (after driving for a distance of approximately 12 miles/20 km). Since the fluidlevel must be checked with the enginerunning, ensure that the vehicle is parked onlevel ground with the handbrake firmly appliedbefore leaving the driver’s seat. Be careful to

keep loose clothing, long hair, etc., well clearof hot or moving components when workingunder the bonnet

Transmission cold

1 Park the vehicle on level ground and applythe handbrake firmly. With the engine runningat no more than idle speed and your footfirmly on the brake pedal, move the selectorlever through all positions, ending in position“P”. Allow the engine to idle for one minute,then check the level within two minutes.2 With the engine still idling and position “P”still selected, open the bonnet and withdrawthe transmission dipstick from the filler tubelocated in the front of the transmission casing,

at the left-hand end of the engine.3 Note the fluid’s condition (see below), thenwipe clean the dipstick using a clean,non-fluffy rag, insert it fully back into the tubeand withdraw it again.4 The level should be up to the “MAX” markon the “+20°C” side of the dipstick (seeillustration).5 If topping-up is required, switch off theignition and add only good quality fluid of thespecified type through the filler tube. If

significant amounts of fluid are being lost

(carefully note the amounts being added, and

how often), check the transmission for leaks

and either repair the fault or take the vehicle to

a Vauxhall dealer for attention.

6 When the level is correct, ensure that the

dipstick is pressed firmly into the filler tube.

Transmission fully warmed up

7 Work exactly as described above, but takethe level reading from the “+80°C” side of the

dipstick. In this case, the level must be

between the dipstick “MAX” and “MIN”

marks.

Checking the fluid’s condition

8 Whenever the fluid level is checked,

examine the condition of the fluid and

compare its colour, smell and texture with that

of new fluid.

9 If the fluid is dark, almost black, and smells

burnt, it is possible that the transmission

friction material is worn or disintegrating. The

vehicle should be taken to a Vauxhall dealer

or automatic transmission specialist forimmediate attention.

10 If the fluid is milky, this is due to the

presence of emulsified droplets of water. This

may be caused either by condensation after a

prolonged period of short journeys or by the

entry of water through the dipstick/filler tube

or breather. If the fluid does not revert to its

normal appearance after a long journey it

must be renewed or advice should be sought

from a Vauxhall dealer or automatic

transmission specialist.

11 If the fluid is varnish-like (i.e. light to dark

brown and tacky) it has oxidised due to

overheating or to over or under filling. If

renewal of the fluid does not cure theproblem, the vehicle should be taken to a

Vauxhall dealer or automatic transmission

specialist for immediate attention.

12 If at any time on checking the fluid level or

on draining the fluid, particles of dirt, metal

chips or other foreign matter are found in the

fluid, the vehicle must be taken to a Vauxhall

dealer or automatic transmission specialist for

immediate attention. It may be necessary to

strip, clean and reassemble at least the valve

body, if not the complete transmission, to

rectify any fault.

8 Radiator inspection andcleaning 1

1 Inspect radiator for leaks or corrosion,

especially around the outlet or inlet

connectors.

2 Clean the radiator with a soft brush or

compressed air. Remove any debris, like dead

insects or leaves.

3 If leaks are visible, replace radiator. Refer to

Chapter 3, if necessary.

9 Idle speed and mixture-adjustment 2

Note:On certain models, the idle and mixtureare automatically adjusted by a control unit,therefore cannot be altered.

Refer to Chapters 4A or 4B as applicable.

10 Throttle linkagemaintenance 2

On models built before 1992, lubricate thethrottle linkage, as described in Chapters 4Aor 4B, as applicable.

11 Exhaust system check 21 With the engine off, check the security ofthe exhaust system. Pay particular attentionto the rubber mountings that suspend theexhaust.2 Start the engine and check underneath forleaks, which can be heard. This job is madeeasier if you have access to a ramp.3 Listen for exhaust leaks from around thefront pipe to exhaust manifold joint.4 For further information, refer to Chapter 4C

12 Wiring check 11 Check all wiring in both the enginecompartment and under the car.2 Ensure that all wiring clips/clamps are secure.3 Pay particular attention to wiring nearcomponents that get hot, i.e. exhaustsystems.4 Make sure that electrical connections aresecure and undamaged.

13 Ignition timing 3

Refer to Chapter 5 for details.

Every 9000 miles or 12 months 1•11

7.4 When checking the fluid level, ensureside of dipstick used corresponds with

fluid temperature

Warning: Voltages produced by

an electronic ignition systemare considerably higher thanthose produced by conventional

ignition systems. Extreme care must betaken when working on the system withthe ignition switched on. Persons withsurgically implanted cardiac pacemakerdevices should keep away from theignition circuits, components and testequipment.



14 Brake fluid renewal 3

Renew the brake and bleed the system.Refer to Chapter 9 for full details.

15 Brake pad check 2

With the front or rear (as applicable) of thevehicle raised, remove the wheels and checkbrake pads for wear. Renew the pads if thelining is below that specified. See Chapter 9,for specifications and full details.

16 Handbrake linkage check 2With the vehicle raised, check the operation

of the handbrake and lubricate the linkages.Refer to Chapter 9, for further details.

17 Power steering fluid check 21 With the engine off, remove the cap fromthe power steering reservoir. It is fitted with adipstick.2 The fluid should be visible up to the ‘MAX’

mark (1), (see illustration). If not, top it upusing specified fluid.3 Start the engine and immediately top-upthe fluid to the ‘MIN’ mark (2).4 Do not allow the reservoir to run dry.5 For details on how to bleed the system,refer to Chapter 10.

18 Power steering pumpdrivebelt check 2

Note: Vauxhall specify the use of a specialgauge. Checking values for use with thisgauge are given in the Specifications inChapter 10, for reference.

Checking

1 The correct belt tension can beapproximated by adjusting the length of thethreaded rod. This should give a beltdeflection of approximately 10.0 mm (0.4 in)under moderate thumb pressure at themidpoint of the belt run between the pulleys. If in doubt, err on the slack side, as anexcessively tight belt may cause pumpdamage.2 Check the condition of the belt and renew itif there are any signs of damage or excessivewear

Adjustment3 Slacken the adjuster and mounting bolts.4 Slacken the adjuster nuts, and adjust thelength of the threaded rod to remove ortension the belt as desired (see illustration).5 Tighten the adjuster nuts, and tighten theadjuster and mounting bolts to the specifiedtorque (see Chapter 10), on completion.6 If a new drivebelt has been fitted, recheckthe tension after a few hundred miles.

19 Rear suspension levelcontrol system check 2

Refer to Chapter 10, for details.

20 Bodywork check

11 Clean the outside of the vehicle. If possible,clean underneath as well. If using a pressurecleaner take care not to damage any electricacomponents, especially in the enginecompartment.2 Check all around for signs of damage orcorrosion and treat accordingly. Repair stonechips when you can to prevent rusting.3 Read Chapter 11, for more details.

21 Lock and hinge check

21 Lubricate locks and hinges on all doors,tailgates (or boot lid) and bonnet.2 Check for wear or damage and ensurecorrect operation of safety catches.3 Check security of the bonnet stay and it’ssecuring clip.4 Read Chapter 11, for further details.

22 Alternator V-belt check 2Note: The new ribbed V-belt, fitted to later

models, can not be adjusted.1 Although special tools are available formeasuring the belt tension, a goodapproximation can be achieved. Tension thebelt so that there is approximately 13.0 mm(0.5 in) of free movement under firm thumbpressure at the mid-point of the longest runbetween pulleys.2 With the mounting bolts just holding theunit, lever the alternator away from the engineusing a wooden lever at the mounting bracketend until the correct tension is achieved. Then

1•12 Every 9000 miles or 12 months

17.2 Topping-up the power steering fluidlevel

18.4 Adjusting the length of the powersteering pump threaded rod

Warning: Brake hydraulic fluidcan harm your eyes anddamage painted surfaces, souse extreme caution when

handling and pouring it. Do not use fluidthat has been standing open for sometime, as it absorbs moisture from the air.Excess moisture can cause a dangerousloss of braking effectiveness.

Old hydraulic fluid is usuallydarker in colour than newfluid.

For a quick check, the thickness of thefriction material on each brake pad canbe measured through the aperture inthe caliper body.



tighten the mounting nuts and bolts. On noaccount lever at the free end of the alternator,

as serious internal damage could be caused.3 For details of replacement, see Chapter 5.

23 Headlamp alignment 2Refer to Chapter 12 for details.

24 Door lock key battery-replacement 1

1 Carefully prise open the outer cover fromthe key. Take care not to lose any of theinternal components, as they are loose.2 Remove the battery and discard it safely.

3 Place the new battery, “+” side up (seeillustration). Check the operation of the key. If the bulb does not light obtain a replacement.4 Replace the outer cover.

25 Road test 1Instruments and electricalequipment

1 Check the operation of all instruments andelectrical equipment.2 Make sure that all instruments readcorrectly, and switch on all electricalequipment in turn to check that it functionsproperly.

Steering and suspension

3 Check for any abnormalities in the steering,suspension, handling or road “feel”.

4 Drive the vehicle, and check that there areno unusual vibrations or noises.

5 Check that the steering feels positive, with

no excessive “sloppiness”, or roughness, and

check for any suspension noises when

cornering, or when driving over bumps.

Drivetrain

6 Check the performance of the engine,

clutch, transmission and driveshafts.

7 Turn the radio/cassette off and listen forany unusual noises from the engine, clutch

and transmission.

8 Make sure that the engine runs smoothly

when idling, and that there is no hesitation

when accelerating.

9 Check that the clutch action is smooth and

progressive, that the drive is taken up

smoothly, and that the pedal travel is not

excessive. Also listen for any noises when the

clutch pedal is depressed.

10 Check that all gears can be engaged

smoothly, without noise, and that the gear

lever action is not abnormally vague or

“notchy”.

11 Listen for a metallic clicking sound from

the front of the vehicle, as the vehicle is driven

slowly in a circle with the steering on full lock.

Carry out this check in both directions. If a

clicking noise is heard, this indicates wear in a

driveshaft joint, in which case, the complete

driveshaft must be renewed (see Chapter 8).

26 Coolant renewal

2

Refer to Chapter 3 for details.

27 Air cleaner element- renewal 2Early round type

1 Release the spring clips from the perimeterof the air cleaner cover.2 Unscrew and remove the small cross-headscrew securing the cover extension to themain body near the inlet duct.

3 Unscrew and remove the three central

cross-head cap nuts securing the air cleaner

to the carburettor, taking care not to drop the

washers and seals (see illustration).

4 Separate the cover from the main body,

then lift out the element (see illustration).

5 Wipe clean the inside surfaces of the cover

and main body.

6 Locate the new element in the air cleaner

body, and refit the cover using a reversal of

the removal procedure.

Square type with air box

7 If desired, to improve access, unclip the

coolant expansion tank hose from the air

cleaner cover.

8 Release the two clips from the left-hand

side of the cover, and unscrew the two

screws from the right-hand side, then lift the

cover sufficiently to remove the element.

9 Wipe clean the inside surfaces of the cover

and main body.

10 Refitting is a reversal of removal, noting

that the element fits with the rubber locating

flange uppermost.

Every 18 000 miles or 24 months 1•13

24.3 Replacing the battery in the door lock key

1 Battery (note, positive ‘+’ side up)2 Bulb

27.4 Removing the air cleaner element -note clip for crankcase ventilation hose

(arrowed)

27.3 Air cleaner-to-carburettor mountingcap nuts

Full service, every 18 000 miles (30 000 km) or 24 months

Warning: Wait until the engine iscold before starting theprocedure. Do not allowantifreeze to come in contact

with your skin or with painted surfaces of the vehicle. Rinse off spills with plenty of water. Never leave antifreeze lying aroundin an open container. Always clean spiltfluids, as it can be harmful if swallowed.



28 Air inlet temperature controlcheck (carburettor modelsonly)

2Refer to Chapter 4A for details.

29 Fuel filter renewal

3

Fuel filters are fitted in various locationsthroughout the range. Some may be ‘in-line’ inthe fuel tank itself, or fitted into thecarburettor.

Refer to Chapters 4A or 4B, as appropriate.

30 Spark plug renewal (SOHC) 21 The correct functioning of the spark plugs is

vital for the correct running and efficiency of

the engine. It is essential that the plugs fitted

are appropriate for the engine. Refer to the

specifications in Chapter 5. If this type is used

and the engine is in good condition, the spark

plugs should not need attention betweenscheduled service replacement intervals.

Spark plug cleaning is rarely necessary and

should not be attempted unless specialised

equipment is available, as damage can easily

be caused to the firing ends.2 Identify each HT lead for position so that theleads can be refitted to their correct cylinders. Then disconnect the leads from the plugs bypulling on the connectors, not the leads.3 Clean the area around each spark plugusing a small paintbrush, then using a plug

spanner (preferably with a rubber insert),unscrew and remove the plugs (seeillustration). Cover the spark plug holes witha clean rag to prevent the ingress of anyforeign matter.4 The condition of the spark plugs will tellmuch about the overall condition of theengine.5 If the insulator nose of the spark plug is

clean and white, with no deposits, this is asign of a weak mixture, or too hot a plug (a hotplug transfers heat away from the electrodeslowly - a cold plug transfers heat awayquickly).6 If the tip and insulator nose is covered withhard black-looking deposits, then this isindicative that the mixture is too rich. Shouldthe plug be black and oily, then it is likely thatthe engine is fairly worn, as well as the mixturebeing too rich.7 If the insulator nose is covered with light tanto greyish brown deposits, then the mixture iscorrect, and it is likely that the engine is ingood condition.8 The spark plug gap is of considerable

importance, because if it is either too large ortoo small, the size of the spark and itsefficiency will be seriously impaired. The sparkplug gap should be set to the figure given inthe Specifications, in Chapter 5.9 To set it, measure the gap with a feelerblade and then bend open, or close, the outerplug electrode until the correct gap isachieved. The centre electrode should neverbe bent, as this may crack the insulation andcause plug failure, if nothing worse (seeillustrations).

10 Before fitting new spark plugs check thattheir threaded connector sleeves are tight.

11 Screw in the plugs by hand, then tightenthem to the specified torque. Do not exceedthe torque figure.

12 Push the HT leads firmly onto the sparkplugs, ensuring that they are connected totheir correct cylinders.

31 Distributor cap and HT leadcheck 3

1 Remove the distributor cap and HT leadsand wipe them clean.

2 Also wipe clean the coil connectionsRemove the rotor arm, then visually check thedistributor cap, rotor arm and HT leads forhairline cracks, and signs of arcing.

1•14 Every 18 000 miles or 24 months

30.9A Tools required for spark plugremoval, gap adjustment and refitting

30.9C Measuring the spark plug gap withfeeler blade

30.9B Measuring the spark plug gap withwire gauge

30.3 Removing a spark plugWarning: Before carrying outthe following operation, refer tothe precautions given in “Safetyfirst!” at the beginning of this

manual, and follow them implicitly. Petrolis a highly dangerous and volatile liquid,and the precautions necessary whenhandling it cannot be overstressed.

It is very often difficult to insert sparkplugs into their holes without cross-threading them. To avoid this, fit ashort length of 8 mm (internaldiameter), rubber hose over the end of the spark plug. The flexible hose actsas a universal joint to help align theplug correctly. Should the plug begin to

cross-thread, the hose will slip on thespark plug, preventing damage to thethread in the cylinder head.

Number the HT leads beforeremoval to ensure correctrefitting.



3 When refitting the distributor cap, checkthat the ends of the HT leads are fittedsecurely to the cap, plugs and coil. Also make

sure that the spring-tensioned carbon brushin the centre of the distributor cap movesfreely, and that the HT segments are not wornexcessively.

4 Inspect the electrical and vacuum

connections of the ignition/engine

management systems, and make sure thatthey are clean and secure.

32 Clutch cable check 2Check the clutch cable adjustment, as

described in Chapter 6.Check also, the condition of the cable.

Inspect the cable strands for fraying, andensure that the cable is correctly routed, toavoid chafing against surroundingcomponents. Renew the cable, as described

in Chapter 6, if excessive wear or damage isevident.

33 Manual transmission fluidcheck 2

Note: Models built after 1994 it is no longernecessary to check levels.

1 Ensure that the vehicle is on level ground.

2 Unscrew the transmission oil level plug,which is located in the rear left of the

differential housing on F10 and F13transmissions, and in the rear right of thedifferential housing on F16 and F20

transmissions (see illustrations). The oil levelshould be up to the bottom of the level plugorifice.

3 If necessary, top-up the oil level through thebreather/filler orifice in the gear selector

cover. Unscrew the breather/filler plug, andtop-up with the specified grade of oil, until oil just begins to run from the level plug orifice.Refit the level plug and the breather/filler plugon completion (see illustrations).

4 Renewal of the transmission oil is notspecified by the manufacturers, and no drainplug is provided. If it is desired to renew the oilas a precaution, the oil may be drained by

removing the differential cover plate. Use a

new gasket when refitting the cover plate. Fill

the transmission through the breather/fillerorifice, as described previously in thisSection.5 Periodically inspect the transmission for oilleaks, and check the gear selector linkagecomponents for wear and smooth operation.

34 Automatic transmissioncheck 21 Carry out a thorough road test, ensuringthat all gearchanges occur smoothly, withoutsnatching and with no increase in enginespeed between changes.2 Check the operation of the kickdown.Check that all gear positions can be engagedat the appropriate movement of the selectorlever and with the vehicle at rest, check thatthe operation of the parking pawl in position“P” prevents it from being moved. Ensure thatthe starter motor will work only with theselector lever in positions “P” or “N”, and that

the reversing lamps light only when position“R” is selected.3 The manufacturer’s schedule calls for aregular check of the electrical control systemusing the special Vauxhall test equipment;owners will have to have this check carriedout by a Vauxhall dealer.4 Periodically inspect the transmission

casing, checking all joint surfaces and sealsfor signs of fluid leaks. If any are found, thefault must be rectified immediately.5 Check also that the transmission breatherhose (under the battery mounting bracket) isclear and not blocked, kinked or twisted.

35 Brake shoe check 2Note: On models fitted with rear brake pads,the handbrake operates brake shoes that arelocated inside the rear brake discs.

Refer to Chapter 9, for details.

Every 18 000 miles or 24 months 1•15

33.3A Transmission breather/filler plug(arrowed) - F16 type transmission

33.3B Topping-up the transmission oillevel - F13 type transmission

33.2B Transmission oil level plug(arrowed) - F16 type transmission (viewed

from below, with driveshaft removed)

33.2A Transmission oil level plug(arrowed) - F13 type transmission (viewed

from above)



36 Timing belt renewal 31 To minimise risk of major damage to theengine the timing belt (or cambelt, as it issometimes called), needs replacing at least,on every major service.2 It is good practise however, not only torenew the belt whenever major engine work iscarried out, but also if you buy a used car withunclear service history.3 Some models are fitted with an inspectioncover to view the condition of the belt. Whilstothers involve a lot more work.4 Full details on checking and replacementare shown in Chapters 2A or 2B, asappropriate.

37 Spark plug renewal (DOHC) 21 This procedure is basically the same shown

in Section 30. However on these models, a

spark plug cover needs to be removed from

the camshaft cover before the plugs can be

removed.

2 Take great care when removing and

refitting spark plugs on these engines (see

illustration). Hairline cracks in the ceramic of

the plug can cause occasional or complete

ignition failure. Damage to the catalytic

converter may also occur.3 Special tool (Vauxhall No. KM-194-B), witha 3 part conical sliding element have been

made available, to reduce the risk of plugdamage (see illustration).4 After refitting the spark plugs, remember toreplace the plug cover.

38 Automatic transmission fluidrenewal 2

Renew the transmission fluid as detailed inChapter 7B.

1•16 Every 36 000 miles or 48 months

37.3 Removing spark plugs using special adapter (DOHC models)

A Torque wrenchB Extension

C J ointD Special adapter (P/N KM-194-B)

37.2 Removing a spark plug -

DOHC model

Major service, every 36 000 miles (60 000 km) or 48 months

Documents

intretinere periodica